Grundfos Motor Book Grundfos Motor Book

82  Grundfos Motor Book

5.  Explosion-proof motors - ATEX

What is ATEX? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
What is an explosive atmosphere? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Source of ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
What kind of equipment does the ATEX directive cover? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 July 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Which obligations do the ATEX directive 99/92/EC imply for the equipment user? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
How an explosive atmosphere is divided into zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Zone 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
How to ensure compliance with the ATEX directives? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Who is responsible for meeting the requirements in the ATEX directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
The manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
The user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
The service engineer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
How to choose the right motor for areas with non-conductive dust? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
The difference between category 2 and 3 motors for use in areas with combustible dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
How to choose the right pump or motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Selection of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Temperature classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
How to choose the right pump or motor for areas with explosive atmosphere? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Grouping of gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Temperature classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Standards and methods of protection EExd, EExe and ExnA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Flameproof motors - protection type EExd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Construction of flameproof motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Characteristics of flameproof motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Typical applications for flameproof motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Increased safety motors - protection type EExe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Construction of increased safety motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Characteristics of increased safety motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Time tE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Typical applications for increased safety motors EEx e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Non-sparking motors - protection type ExnA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Construction of non-sparking motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Characteristics of the non-sparking motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Typical applications for non-sparking motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Combined equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Assemblies and their characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Installations and electric connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
What Grundfos can offer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Grundfos Motor Book  83

5. Explosion-proof motors - ATEX Grundfos Motor Book

What is ATEX?

What is ATEX?
ATEX (ATmosphère EXplosible) refers to two new
EU directives about danger of explosion within
different areas. The first ATEX directive (94/9/
EC) deals with requirements put on equipment
for use in areas with danger of explosion. The
manufacturer has to fulfil the requirements
and mark his products with categories. The sec-
ond ATEX directive (99/92/EC) deals with the
minimum safety and health requirements that
the owner of the equipment has to fulfil, when
working in areas with danger of explosion.

What is explosive atmosphere?

According to the new directives, dust is now
considered an explosive atmosphere.
An explosive atmosphere is an atmosphere that
develops explosively because an uncontrolable
combustion. Explosive atmosphere consists of
air and some sort of combustible material such
as gas, vapours, mists or dust in which the
explosion spreads after ignition. Typical exam-
ples of productions where combustible dust
is of major concern, is the handling of cereals,
animal feed, paper, wood, chemicals, plastics
and coal.

Examples of sources of ignition that can cause

the atmosphere to explode:
• Electrical sparks
• Flames
• Hot surfaces/ spots
• Static electricity
• Electromagnetic radiation
• Chemical reaction
• Mechanical forces
• Mechanical friction
• Compression ignition
• Acoustic energy
• Ionising radiation

84  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

What is ATEX?

An explosion is an uncontrolled combustion wave

that produces a rapid increase in temperature
and pressure. For an explosion to take place, three
elements have to be present at the same time:
fuel, (such as explosive gas) an oxidiser, (such as
the oxygen in the air) and a source of ignition,
(such as electrical sparks). The combination of
these three elements is generally referred to as
the Fire Triangle.

To generate a potentially explosive atmosphere,

the mixture of fuel and oxidiser has to have a cer-
tain concentration. This concentration depends on
the ambient pressure and the content of oxygen in
the air, and is referred to as the explosion limits.
Outside these limits, the mixture of fuel and oxi-
diser will not ignite, but has the potential to do
so if the proportions change. For an explosive
atmosphere to form, a certain concentration of
combustible material must be present.

Grundfos Motor Book  85

5. Explosion-proof motors - ATEX Grundfos Motor Book

What is ATEX?

Actually the mechanism is simple: When the con-

centration of combustible material is too low (lean
mixture) or too high (rich mixture), no explosion
will take place. In that case only a slow combustion
or none at all will occur. It is solely within the range
of the upper and the lower explosion limit that
the mixture of fuel and oxidiser reacts explosively
when exposed to a source of ignition.

Substance Lower explosion Upper explosion

designation limit [Vol. %] limit [Vol. %]

Acetylene 2.3 78.0

(self-decomposing)

Ethylene 2.3 32.4

Gasoline 0.6 8

Benzol 1.2 8

Natural gas 4.0 - 7.0 13.0 - 17.0

Heating oil/diesel 0.6 6.5

Methane 4.4 16.5

Propane 1.7 10.9

Carbon disulphide 0.6 80.0

Town gas 4.0 - 6.0 30.0 - 40.0

Hydrogen 4.0 77.0

Source: Explosion Limits of selected Gases and

Vapours Extract from the table ”Safety characteris-
tics of flammable gases and vapours” by K. Nabert
and G. Schön - (6th addendum)

Source of ignition
For an explosive atmosphere to ignite, a certain
quantity of energy has to be present. Minimum
ignition energy is defined as the smallest possible
amount of energy that is converted during the
discharge of a capacitor. It is the amount of energy
that is just enough to ignite the most ignitable
mixture of fuel and oxidiser. The minimum igni-
tion energy is around 5 - 10 joules for hydrogen and
a few joules for certain types of dust.

86  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

What is ATEX?

What kind of equipment does the ATEX

directive cover?
• Safety equipment and safety systems exposed
to explosive gasses or dust.
• Safety, control and adjustment devices, which
ensure a safe operation of production material
and control equipment.
• Electrical, mechanical, hydraulic and pneu-
matic equipment including pumps and electric
motors.

1 July 2003
Companies that produce, use or distribute this kind
of equipment must comply with the basic safety
and health requirements in the ATEX directive.
The ATEX directive 94/9/EC does not have retroac-
tive effect. However, already existing products
must be subject to analysis. In case of defects
(wear etc.), the old products must be replaced with
equipment that complies with the ATEX directive.
In addition, products that are specially made for
use in areas with high explosion risk (zone 0 or 20)
should only be marketed when they fully comply
with the ATEX directive. Grundfos pumps, which
were originally supplied with an Ex motor, may
only be replaced or resold when they comply with
the ATEX directive.

Which obligations do the ATEX directive

99/92/EC imply for the equipment user?
To prevent explosion, the user of the equip-
ment must:
• Take the necessary technical and organisa-
tional precautions.
• Make a complete estimate of the risk of
explosion
• Divide potential explosive risk areas, into
zones.
• Indicate the danger zones clearly.

Grundfos Motor Book  87

5. Explosion-proof motors - ATEX Grundfos Motor Book
How an explosive atmosphere is
divided into zones?

How an explosive atmosphere is

divided into zones
The ATEX directive 99/92/EC distinguishes
between two types of explosive atmospheres: gas
and dust. Areas subjected to these two kinds of
explosive atmospheres are each divided into three
zones. The zone’s characteristics are identical for
gas and dust, but their numbering is different.
Zones 0, 1, 2 refer to gas and zones 20, 21, 22 refer
to dust.

Zone 0 / 20: Constant danger

Permanent presence of explosive gasses or com-
bustible dust. Minimum category 1 equipment.

Zone 1 / 21: Potential danger

Occasional presence of explosive gasses or com-
bustible dust during normal duty. Minimum cat-
egory 2 equipment.

Zone 2 / 22: Minor danger The link between zones and equipment categories, is a
minimum requirement. If the national rules are more
Presence of explosive gasses or combustible dust
strict, they are the ones to follow
not likely to occur or only for a shorter period of
time. Minimum category 3 equipment.

Grundfos manufactures pumps, with motors in

both category 2 and category 3. The illustration
on your right shows the division of an area into
zones with different levels of danger of explo-
sion. For each of the three zones it is only a cer-
tain category of equipment – in this case motors
– that can be used due to danger of explosion.

The owner of the equipment is responsible for

defining whether an area is to be considered haz-
ardous within the regulations stated in the ATEX
directive. However, if the user has any doubts
about the definition of hazardous areas, he has to
contact the proper authorities for advice.

In Denmark the proper authority is the local

Emergency Management Agency.

88  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
Who is responsible for meeting the
requirements in the ATEX directive?

How to ensure compliance with the

ATEX directives?
Equipment and zones have to comply with the
ATEX directive. The CE marking is the proof that
the equipment is manufactured according to all
the basic requirements and assessment proce-
dures that apply for every EU member state.

Who is responsible for meeting the

requirements in the ATEX directive?
Depending on whether you are the equipment
manufacturer, owner or service engineer there
are certain safety requirements that you have
to fulfil.

The manufacturer
As manufacturer Grundfos is exclusively respon-
sible for producing equipment that meets the
requirements stated in the EU directive.

The user
The equipment owner has to inform Grundfos of
what kind of equipment he needs, as to:
• Category, e.g. 2G
• Temperature, e.g. 125°C
• Type of motor protection, e.g. EExe II T3

In addition, the equipment owner has to use

the product according to the defined zones and
thereby take any possible risks into account.
Likewise, the equipment owner is responsible
for ensuring that the equipment runs safely
through continuous maintenance. As per 1 July
2003, new installations must meet the require-
ments stated in the ATEX directive. If the equip-
ment owner is also the manufacturer, the owner
has to fulfil the requirements for both. Already
existing installations have to comply with the
requirements in the ATEX directive 99/92/EC by
the latest on the 30rd june 2006.

Grundfos Motor Book  89

5. Explosion-proof motors - ATEX Grundfos Motor Book
Who is responsible for meeting the
requirements in the ATEX directive?

The service engineer:

Service engineer are not covered by the directive
94/9/EC. However, Service engineers have to make
sure that the work they conduct meets the safety
demands that apply for products and equipment,
so that the safety is not put at risk. Notified bodies
such as KEMA and PTB have the authority to issue
qualification certificates to service engineers as
a proof of their know-how. The supplier’s service
and quality department can issue qualification
certificates as well.

The requirements in the ATEX directive are not

entirely new to electric motors. Previously, they
were placed under the IEC60079 standard and
under local standards in countries around the
world. The ATEX directive includes references
to EN standards that contain the same require-
ments as the IEC60079 standard. The IEC60079
standard still applies for electric motors in other
parts of the world.

90  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
How to choose the right motor for
areas with non-conductive dust?

How to choose the right motor for

areas with non-conductive dust?
When the area has been divided into zones, it is X˚ = Y˚+ 75˚C
time to move a step further and decide which
pump or motor to install in that specific area. X ˚C = Ignition temperature
Depending on the zone classification, certain for a 5 mm dust layer
rules have to be respected:
Y ˚C = Motor surface temperature,
If an area is classified as zone 20, (area with con- e.g. 125˚ C
stant danger of explosion) it excludes any use of
pumps or motors. If the area is classified as zone
21, (area with potential danger of explosion) the
motor has to be approved by a notified body
In areas with dusty air, dust
before it is installed. The motor manufacturer is is likely to be found on the
responsible for having his prototype approved pump and the motor
by the notified body for use in specific areas. If
the area is classified as a zone 22 area, (area with
minor danger of explosion) any motor that is
dust ignition proofed by the manufacturer, can
be use unless conductive dust is present. Z˚ = Z˚ + Y˚/3
When deciding which motor to use in an explo- Z ˚C = Ignition temperature for dust cloud
sion-risk area, it is important to take dust’s
ignition temperature into account in order to Y ˚C= Motor surface temperature,
e.g. 125˚C
avoid explosion.
• The ignition temperature for a cloud of dust has
to be at least 1/3 higher than the motor’s marking
temperature.
• The ignition temperature of a 5 mm layer of dust
has to be minimum 75°C higher than the motor’s
marking temperature (see previous page).

It is exclusively the user’s responsibility to see to it

that the layer of dust does not exceed the 5 mm,
through regular maintenance.
Ignition temperatures for different types of dust are
available in reference tables like the one shown on Ignition temperatures
your right. Material Cloud 5 mm layer
Wheat 420°C 200°C
Corn 400°C 250°C
Sugar 350°C 420°C
Lignite 450°C 200°C
Sulphur 40°C 250°C
Source: BIA-report 13/97
Combustion and explosion characteristics of dust

Grundfos Motor Book  91

5. Explosion-proof motors - ATEX Grundfos Motor Book
The difference between category 2
and 3 motors

The difference between category 2

and 3 motors for use in areas with Zone 20
combustible dust
Dust Conducting Non-conducting
Category 2
Index protection IP6X IP6X
In order to avoid static electricity to cause ignition,
the cooling fan on a category 2 dust ignition-proof
Product marking II 1 D II 1 D
motor for use in zone 21 (area with potential danger
of explosion) is made of metal or other anti-static Motors may not operate in zone 20.
materials. Likewise, to minimise the risk of ignition,
the external ground terminal is subject to more
severe demands of construction. The temperature, Zone 21
which is indicated on the motor’s nameplate, cor-
Dust Conducting Non-conducting
responds to the running performance during the
worst conditions allowed for the motor. Motors for
Index protection IP6X IP6X
use in zone 21 (areas with potential danger of explo-
sion) has to be IP6X protected, that is completely
Product marking II 2 D II 2 D
protected against dust.

Category 3
Zone 22
The temperature indicated on a category 3 dust
ignition - proof motor for use in zone 22 (areas Dust Conducting Non-conducting
with minor danger of explosion) corresponds to
the running performance under the worst condi- Index protection IP6X IP5X
tions allowed for that specific motor. A motor
for use in zone 22 has to be IP5X protected, that
Product marking II 2D II 3 D
is protected against dust and have an external
grounding terminal.

92  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
How to choose the right pump or
motor

How to choose the right pump or

motor
You are on the lookout for a motor that can be
integrated in your sugar production plant. Waste
of sugar, in the shape of dust, is a natural con-
sequence of your production. In order to create
a safe working environment with no danger of
explosion, you have to consider several factors
when choosing motors for your pumps.

Sugar dust is a non-conducting kind of dust

The self-inflammation temperature for sugar

depends on its concentration:
• For sugar in a layer, the self-inflammation
temperature is 420°C
• For sugar in a cloud, the self-inflammation
temperature is 350°C

Selection of equipment
The motor’s Index Protection classification, (IP)
determines in what zone the motor is allowed
to operate.

IP6X motors can be used in zone 21

and,
IP5X motors can be used in zone 22

Temperature classes
When you determine the motor’s temperature
class, you have to take the ignition temperature
for different concentrations of sugar dust into
account.
•  Sugar dust in a layer

The ignition temperature for a 5 mm layer of

sugar dust is 420°C and as mentioned previously,
its minimum ignition temperature must be 75°C
higher than the motor’s rated temperature. So,
the maximum temperature that a layer of sugar
dust can attain before it ignites is calculated in the
following way:
420°C – 75°C = 345°C

Grundfos Motor Book  93

5. Explosion-proof motors - ATEX Grundfos Motor Book
How to choose the right pump or
motor

The maximum product temperature is indicated

on the motor’s nameplate: II 2D T125°C maxi-
mum.

Normally, standard DIP motors are marked with

125 °C as the maximum product temperature. And
as you can tell from the example above, 125°C is
thus lower than the 345°C.
•  Sugar dust in a cloud

The ignition temperature for sugar in a cloud

of dust is 350°C, and as mentioned previously,
its minimum ignition temperature must be 1/3
higher than the motor’s rated temperature. So,
the maximum temperature that sugar dust in a
cloud can attain before it ignites, is calculated in
the following way:
2/3 of 350°C = 233°C

The maximum product temperature is indicated

on the motor’s nameplate: II 2D T125°C maxi-
mum.

Normally, standard DIP motors are marked with

125°C as the maximum product temperature. And
as you can tell from the example above, 125°C is
thus lower than the 233°C.

If both sugar in a layer and sugar dust in a cloud

is present at the same time, the temperature
indication on the equipment has to correspond
to the maximum surface temperature of both
pump and motor. And as mentioned before, 125°C
is the standard rating most motor manufactures
indicates on the nameplate for DIP motors.

94  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
How to choose the right pump or
motor for areas with explosive gases

How to choose the right pump or

motor for areas with explosive
gases
When the area has been divided into zones, it is
time to move a step further, and decide which Typical gas hazard Gas group
motor to install in that specific area. There are
Acetylene IIC
certain factors to take into consideration when
determining which motor to use in an explosive
Hydrogen IIC
atmosphere.

Ethylene IIB
Grouping of gases
Gases are divided into the following two explo-
Propane IIA
sion groups depending on which kind of indus-
try the equipment is to operate in: Explosion I (firedamp) mining
group I an II. Methane
IIA industrial
• Explosion group I: Mines and other under-
The content of this table only applies
ground industries
to EExd motors
• Explosion group II: Off-shore industries and
industries above ground

Explosion group II is divided into 3 subgroups, II A, II

B and II C. The group only applies for EExd motors,
which corresponds to the type of gas the motor is
made to withstand if an internal explosion occurs.

A gas which is classified as a group IIC gas, des-

ignates that it is the most explosive gas possible.
The table at your right shows examples of dif-
ferent kinds of gases and their explosion group
classification.

The danger of gas explosion increases from group

IIA to group IIC; Depending on which group the
specific gas belongs to, the requirements for
pumps and motors increase accordingly. The
higher the dangers of explosion, the stricter are
the requirements to the equipment. Therefore,
it is a requirement that electrical equipment
carries a clear marking of what explosion group it
belongs to. An electric motor that is approved as
IIC equipment may also be used for other explo-
sion groups – since IIC is considered the most
dangerous explosion group.

Grundfos Motor Book  95

5. Explosion-proof motors - ATEX Grundfos Motor Book
How to choose the right pump or
motor for areas with explosive gases

Temperature classifications
Auto-ignition temperature is the temperature at
X °C ≥ T1, T2, T3…
which a gas will ignite spontaneously without any
other source of ignition. When hot surfaces are
X °C = Ignition temperature for gas
in contact with an explosive atmosphere, auto-
ignition is likely to occur. The table below shows
Y °C = Motor temperature; T1, T2, T3...
the classification, which is used to indicate the
maximum surface temperature that a given piece
of electrical equipment can reach when it is run-
ning normally. Generally, the maximum surface
temperature is based on a surrounding tempera-
ture of 40°C. Equipment’s T-classification can be
compared with the auto-ignition temperature for
gases. Once the T-classification is determined,
decisions concerning the equipment’s use in areas
with explosive atmosphere are made.

The table below shows the temperature clas- Pump and motor in areas
sification for different types of gases classified exposed to explosive gases
according to explosion group IIA, IIB or IIC.

Regarding EExd motors the temperature clas-

sification is an expression of the maximum Maximum Categorisation of gases and vapours
Temp.
surface
external temperature of the motor . class.
temperature C IIA IIB IIC
Methane
In connection with EExe and ExnA motors, the T1 450°C Hydrogen
Ammonia
temperature classification is an expression of the
temperature inside and outside the motor. T2 300°C Butane Ethylene Acetylene
Kerosene
As far as dust is concerned, the most common T3 200°C
Cyclohexane
external temperature designation is the precise Acetalde- Diethyl
T4 135°C
temperature of the motor. hyde Ether
T5 100°C
Carbon
T6 85°C
Disulphide

Temperature classification for gases

The categories only apply to EEx d motors

96  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
Standards and methods of protection
EExd, EExe and ExnA

Standards and methods of protec-

tion EExd, EExe and ExnA
Different techniques are used to prevent electrical
equipment from becoming a source of ignition.
The following table shows the concepts and stan-
dards for electrical appliances for gases, vapours
and mists.

In the case of electric motors, protection type

d (flameproof), e (increased safety) and n (non-
sparking) are applied. On the following pages, we
will present the three protection types in detail.

Standards Use in ATEX

Type of
Code CENELEC IEC category/ Principle Application
Protection
EN 60079 zone 
General
- 50014 -0 - Basic electrical requirements All equipment
requirements

Category 2 Electric components immersed in oil

Oil immersion o 50015 -6 Zone 1
excluding explosive atmosphere from Transformers
igniting

Enclosure housing equipment is purged to Switching and

Category 2 remove explosive atmosphere and pres-
Pressurised p 50016 -2 Zone 1 surised to prevent ingress of / from the
control cabinets,
surrounding atmosphere large motors

Category 2 Electric parts are surrounded with

Electronic devices
Powder filled q 50017 -5 Zone 1
powder e.g. quartz to prevent contact
e.g. capacitors, fuses
with an explosive atmosphere

Category 2 Enclosure housing of electric equipment

AC motors, Control
Flameproof d 50018 -1 Zone 1
will not ignite surrounding atmosphere, if
Panels, light fittings
there is an internal explosion,

Additional methods are used to AC motors, terminal

Increased Category 2 eliminate arcs, sparks and hot surface and connection boxes,
e 50019 -7 capable of igniting flammable light fittings, squirrel
safety Zone 1
atmosphere cage motors

ia Category 1 Measurement and

50020 - 11 Zone 0 Electric energy in equipment is limited so control equipment
Intrinsic safety that circuits cannot ignite an e.g. sensors,
Category 2 atmosphere by sparking or heating
ib 50020 - 11 Zone 1 instrumentation

Category 2 Electric components embedded in Measurement and

Encapsulation m 50028 - 18 Zone 1
approved material to prevent contact control devices,
with explosive atmosphere solenoid valves

Type of Category 3 AC motors, terminal

nA 50021 - 15 Non-arcing and non-sparking
boxes, light fittings
protection ‘n’ Zone 2

Note: Group II dust atmospheres are covered by CENELEC EN 50281-1-1 and EN50281-1-2 standards

Grundfos Motor Book  97

5. Explosion-proof motors - ATEX Grundfos Motor Book
Standards and methods of protection
EExd, EExe and ExnA

Flameproof motors
– protection type EExd
In this section, you can read about the construc-
tion and the characteristics of a flameproof
motor. Likewise, you will find information about
the kind of applications flameproof motors are
installed in.

Construction of flameproof motors

First of all, flameproof EExd motors are category
2G equipment for use in zone 1. The stator hous-
ing and the flanges enclose the flameproof motor
parts that can ignite a potentially explosive atmo-
sphere. Because of the enclosure, the motor can
withstand the pressure resulting from an explo-
sion of an explosive mixture inside the motor.
Propagation of the explosion to the atmosphere
that surrounds the enclosure is hereby avoided
because the explosion is cooled down by means
The explosion occurs inside the motor and is
of flame paths. The size of the flame paths is
lead out of the motor through the flame paths.
defined in the EN 50018 standard. The temperature classification for flameproof EExd
motors is valid for external surfaces
Furthermore, the temperature classification is
valid for external surfaces.
Flame path
Characteristics of flameproof motors
The following features are what characterize a
flameproof motor.
• Flame paths
• Reinforced frame, terminal box and end shields
• Greater contact surface between motor
components
• Reduced clearance between motor shaft and
bearing cap to avoid transmission of sparks to
the external environment
• Pressure test of all components (frames, end
shields, terminal boxes, and terminal box covers)
• Compulsory third body certification by, e.g.
DEMKO, PTB, KEMA or BASEEFA
• Ex approved cable entries

98  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
Standards and methods of protection
EExd, EExe and ExnA

Typical applications for flameproof

motors
The most frequent applications for flameproof
motors include pumps, fans, blowers, crushers,
conveyor systems, mills, cranes and other appli-
cations located in areas that require explosion
proof motors.

In certain applications the motor may carry two

protection types: One for the stator housing, “d”
and one for the terminal box, “e”.

In this case, the motor is marked “de”. So, the only

difference between a motor that is marked EExde
and a motor that is marked EExd is the configura-
tion of the terminals and the terminal box. The
terminal box with increased safety terminal block
prevents any source of ignition such as sparks and,
excessive heating from taking place.

The main characteristics of EExde motors are:

• Terminal box components as well as con-
nection
cables must be firmly fastened
(in order not to move)
• Special terminal block to avoid arcs and sparks.
(increased safety terminal block)
• Double grounding must be provided
(one on the stator housing and the other on the
terminal box cover)

Increased safety motors

- protection type EExe
In this section, you can read about the construc-
tion and the characteristics of an increased safety
motor. Likewise, you will find information about
what kind of applictions increased safety motors
are installed in.

Grundfos Motor Book  99

5. Explosion-proof motors - ATEX Grundfos Motor Book
Standards and methods of protec-
tion EExd, EExe and ExnA

Construction of increased safety motors

Increased safety motors (type e) are not flame-
proof and not built to withstand an internal explo-
sion. The construction of such a motor is based
on increased security against the risk of excessive
temperatures and occurence of sparks and arcs
during normal operation, and when one predict-
able error occurs. The temperature classification
for increased safety motors is valid for both inter-
nal and external surfaces. Therefore it is important
to observe the stator winding’s temperature.

Characteristics of increased safety motors

The following features are what characterize an
increased safety motor:
•  Reduced power output versus frame size.
• Special attention to air gap concentricity and
clearance of all rotating parts.
•  Components subject to impact tests. For increased safety motors EExe,
• The temperature rise has to be 10K lower no sparks may occur. The temperature classification
covers both internal and external surfaces
than the permitted maximum for that class
of insulation e.g.: ∆T = 70°C for Class B
temperature rise.
• PTC (Positive Temperature Coefficient) therm-
istors 110°C (normal 155°C).
• Maximum surface temperature T1, T2 or T3.
• Compliance with tE characteristic (the time
taken at maximum ambient temperature for
stator windings to be heated up when carrying
the stator current or the locked rotor current.)
• Special terminal board that ensures the speci-
fied creepage and clearance, with non-twist
terminations.
•  Terminal box with IP55 enclosure.
• External grounding on the frame is mandatory.
• Frame grounding must be connected with ter-
minal box grounding.
• Drip cover must be applied on vertical appli-
cations.
• Compulsory third body certification by, e.g.
DEMKO, PTB, KEMA or BASEEFA.

100  Grundfos Motor Book

 5. Explosion-proof motors - ATEX
Standards and methods of protection
EExd, EExe and ExnA

Time tE
Time tE is the time it takes for the motor winding,
when starting current or locked rotor current runs
through it, to reach the temperature limit. The
calculation of Time tE is based on the achieved
temperature under normal duty and it takes the
maximum ambient temperature into consider-
ation as well.

When the rotor is locked, the motor is switched

off by protection device, before time tE gets to
the end.

The supplier is responsible for indicating time

tE on the motor’s rating plate and in the data
booklet.
Time tE is the time it takes the motor wind-
ing to reach the maximum temperature.
The interval OA in the illustration represents the
Time tE is the equivalent to safe stall time or
maximum ambient temperature, and the interval
locked rotor time for standard motors
OB represents the maximum temperature the
stator windings reach under normal operation. If
for example the rotor locks and the temperature
consequently increases, the protective device turns
off the motor. This scenario is illustrated in interval
2 of the chart.

In interval 2, the motor temperature increases

quickly and it has to be lower than its maximum
surface temperature classification. In order to
avoid an explosion, it is therefore important that
the motor is put to a stop before it reaches its
maximum surface temperature. If you need to
know the value tE of an EEx e motor you can find
it in the manufacturer’s data booklet or on the
motor nameplate.

Typical applications for increased safety

motors EEx e
In areas, where a certain amount of explosive
atmosphere is present, explosions can occur even
when the equipment is running normally. The
areas are classified as zone 1 and 2, and the equip-
ment as explosion group II. The most common
gases that can cause an explosion in these areas
include: Ammonia, butane, methane, ether and
hydrogen.

Grundfos Motor Book  101

5. Explosion-proof motors - ATEX Grundfos Motor Book
Standards and methods of protec-
tion EExd, EExe and ExnA

Non-sparking motors - protection type ExnA

In this section, you can read about the construc-
tion and the characteristics of non-sparking
motors. Likewise,you will find information about
what kind of applications non-sparking motors are
installed in.

Construction of non-sparking motors

Non-sparking motors type nA cannot by any
means ignite a potentially explosive atmosphere,
under normal operation. As the name non-spark-
ing implies, the motor is not likely to cause an igni-
tion. Non-sparking motors type ExnA, are category
3G equipment for use in zone 2. The construction
of the ExnA motor is more or less similar to the
standard IP55 motor.

Characteristics of the non-sparking motor

With non-sparking motors,
The following features are what characterize a
no ignition is likely to occur
non-sparking motor:
• Special attention to air gap concentricity and
clearance of all rotating parts
• Components subject to impact test
• Permissible internal or external surface tem-
perature classification, T3,T2, T1
• Minimum IP54
• Manufactures can without consulting any
authorities declare their motors as ExnA pro-
tected motors
Some of the above features are similar to the
increased safety motor, type e, except that the
standard output is obtained from the motor with-
out any derating and any tE monotoring. Because
these motors are used in areas classified as zone 2,
internal and external surfaces are always limited
to temperature classification T3,T2, T1, except dur-
ing start-up.

Typical applications for non-sparking motors

The areas are classified as Zone 2, Non-spark-
ing motors are typically used in environments
where an explosive atmosphere will probably
not be present under normal operation. The
most common gases that can cause an explo-
sion in this area are: Ammonia, butane, meth-
ane, ether and hydrogen.

102  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

Combined equipment

Combined equipment
Combined equipment consists of multiple pieces
of equipment, components or protective systems EEx motors and frequency con-
that provide a specific function. Combined equip- verter operation
ment is used when we deal with an explosive
atmosphere. Only when the following three condi-
placed out of zones
tions are met, we consider equipment as being
Frequency converter
combined equipment:
• Composition of pieces of equipment, compo-
nents and protective systems with the purpose Motor protection device
of fulfilling a specific function
• The pieces of equipment cannot be replaced
individually
• Combined equipment is placed on the market
as a unit

Therefore, motors with variable frequency con-

verters, motor protection devices and other con-
trol and surveillance systems are considered as
combined equipment.

Motors running in hazardous areas with a con-

verter supply are, depending on the country in EEx d
which they operate, submitted to various local
standards. The operation of the converter must
be certified specially and thus, the manufacturer’s placed out of zones
instructions have to be followed closely. Frequency converter

Therefore, motor, and protective device marked

with the type protection code “EEx e” is consid- Motor protection device tE
ered as one single unit and the operating data
are determined in the common test certificate
issued by for example PTB. Frequency converters
are placed away from the zones and are therefore
not marked with EEx e. However, the frequency
converter type and the special data has to be indi-
cated on the motor certificate. When choosing a
frequency converter for an EEx e motor, it is impor-
tant to follow the motor supplier’s instructions as
to what type to choose, which manufacturer to
1 certificate
choose etc..
for all parts
Motor + tE protection
The magnitude of the voltage peaks from the con-
Frequency converter
verter can have a negative impact on the motor
and cause an additional temperature increase. EEx e type

Grundfos Motor Book  103

5. Explosion-proof motors - ATEX Grundfos Motor Book

Installations and electric connections

The maximum value of the voltage peaks in a

converter, cable and electrical motor system must
never exceed the value prescribed by the manu-
facturer.

If EEx d motors are certified with a protection

for the thermal protectors in the winding, all
frequency converters can be used without any
further approval.

Assemblies and their characteristics

Assemblies are configurations of devices and
equipment, which normally consist of multiple
pieces of equipment or combined equipment
and are mechanically connected to each other by
means of tubes or wiring. The following features
are what characterise assemblies:
• Single pieces of equipment, generally replace-
able and which are subject to conformity
assessment separately.
Motor and pump are approved separately in
Industrial pumps powered by electric motors are connection with combined equipment.
examples of assemblies. Motor and pump are
replaced separately within the scope of confor- Therefore motor and pump are perceived as individual
mity assessment procedures. They are connected assemblies with individual certificates
to each other by standard means and are often
produced by different manufacturers.
Thus, all Grundfos pumps can be fitted with an
approved EX-motor of any type as long as they
comply with the Grundfos specific construction
demands.

Installations and electric

connections
When it comes to installations and electric connec-
tions, national regulations are to be followed. The
cable entries have to be approved for explosion-
proof areas and they must be protected against
self-loosening. Always consult the national edi-
tion of the EN 60079-14 standard EN 60079-14
(Installation of Electrical Apparatuses).

104  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

Service and maintenance

Service and maintenance

To ensure that the electric motor always provides
maximum protection and delivers a high perform-
ance, it is important to carry out regular service
and maintenance. However, in most cases only
authorised personnel is allowed to carry out service
and maintenance. Regulations concerning service
and maintenance vary according to the country in
which the motor is to operate. Therefore, you have
to follow the specific rules that apply for explosion
proof motors in your country.

On the following page, we have listed some general

Danish rules you need to be aware of when you carry
out service and maintenance on explosion-proof
motors. But again, we need to stress that rules
con-cerning service and maintenance are placed
under local legislation and that you need to con-
sult them, to be sure that you take the necessary
precautions when you deal with explosion-proof
motors.

• Repair of explosion-proof motors has to be carried out by the manufacturer himself. Further, the
motor manufacturer has the possibility to assign the repair work to other authorised companies,
even across national borders.

• Control and test of repaired motors.

• It is only possible to replace motor parts if it does not affect the motor’s protection type or the
motor’s maximum temperature. If motor parts are replaced, the motor has to be tested before
it is put into operation again.

• If it is possible to disconnect the motor during repair, any qualified company can carry out the
service as long as it does not affect the explosion protection of the motor.

• When the motor has undergone repair that may have an impact on the motor’s protection type,
the motor has to go through a new unit control and unit test.

Now that we have presented some general guide-

lines in connection with repair of explosion-proof
motors, it is time to move a step further. What fol-
lows are some examples of repair work on original
parts, which does not affect the motor protection
type and thus can be carried out by any qualified
company.

Grundfos Motor Book  105

5. Explosion-proof motors - ATEX Grundfos Motor Book

Service and maintenance

• Replacement of damaged cable entries

• Replacement of external fastening equipment
such as bolts and screws
• Replacement of thermal relay
• Replacement of bearings and cooling fans
• Welding of cracked motor foot,
(if it is not a part of the enclosure)
• Replacement of damaged gaskets
Now that we know what kind of repair work
that does not affect the motor’s protection type,
let us have a look at the type of repair work that
does affect the motor’s protection type, and
thus requires authorised personnel:

Whenever it is necessary to carry out repair

work that might affect the motor’s explosion

•  Drilling of holes in EEx d motor enclosure, flanges, stator housing etc.

•  Machining, grinding, painting etc. of flame paths on EEx d motors.

•  Replacement of components in EEx d motors by unoriginal components, i.e.

self-made flanges.

• Fitting of additional terminals in EEx e terminal box if the terminals are not mentioned in the certificate.
Only applies for EEx d motors.

•  Rewinding of EEx e motors.

• Replacement of factory-mounted connections between EEx d stator housing and EEx e terminal box by
EEx de motors.

proofness, an expert has to approve the repair.

However, if the expert cannot give his approval
of the repair work, the motor must not be recon-
nected to the pump.

Having presented what kind of repair work autho-

rised or qualified personnel may carry out on
explosion-proof motors, let us have a look at the
type of repair the user is allowed to carry out
himself on EExe and EExd motors.
• Repair of external parts, which do not affect
the motor’s protection type

106  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

What Grundfos can offer

Should it be necessary to open the motor, you need

to follow the local rules in your country. In connec-
tion with EExd motors this is especially important
because the dismantling and the assembly of the
motor might affect the flame paths.

We recommend keeping a log concerning the

repair work that has been carried out and the
components that have been replaced on each Ex
motor.

If there is any doubt about whether the repair

work will affect or might affect the protection
type of the equipment, the repair always has to be
carried out by qualified personnel.

What Grundfos can offer

Pumps in the Grundfos CR range are approved as
category 2 and 3 equipment and can be used in
areas classified as zone 21 and 22 for dust and in 1
and 2 for gas.

Certain types of Grundfos pumps and motors are

not approved for operation in hazardous areas.
Therefore, Grundfos has a close cooperation with
different EX motor manufactures. All of them
supply flameproof, increased safety, dust ignition
proof and non-sparking motors.

Likewise, the Grundfos motors MGE, MMGE, MG

and MMG are not approved for use in hazardous
areas with explosive gases.

Grundfos Motor Book  107

5. Explosion-proof motors - ATEX Grundfos Motor Book

What Grundfos can offer

Type of
EEx d EEx de EEx e EEx nA
protection
Explosion-proof with
Designation Explosion-proof increased safety Increased safety Non-sparking
terminal box

Explosion not allowed

Avoid internal Ensure non-occurrence
to propagate to the Ensure no arcs or
explosion to propagate of arcs or sparks under
Objective external environment, sparks during normal
to external normal operation
with special attension operation or starting.
environment
to terminal box

Time tE Not applied Not applied Applied Not applied

Similar to standard Similar to standard

Rugged frame, with motor, with special motor, with special
Construction Rugged frame special characteristics characteristics on the characteristics on the
on the terminal box terminal box and the terminal box
rotating parts
Output/
Standard Standard Reduced Standard
frame ratio
Explosion-proof
Increased safety Increased safety
Terminal box Explosion-proof with increased safety
terminal box terminal box
terminal box

This table gives an overview of the different types

of Ex motors. Whether you chose one or the other
type of motor depends on the code of practice.
However, the choice between an EExd and an
EExe motor is often determined by tradition and
by the type of application in which the motor is to
operate.

108  Grundfos Motor Book

 5. Explosion-proof motors - ATEX

What Grundfos can offer

KEMA 04TEX2139 X

KEMA 04TEX2139 X

Grundfos Motor Book  109